Remove floorpan - Alfa Romeo Bulletin Board & Forums
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post #1 of 11 (permalink) Old 08-16-2019, 06:59 AM Thread Starter
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Remove floorpan

I was under my S2 replacing the gearbox and noticed a patch of a crossed pattern in the bituminous gunk that the PO had covered the bottom of the car with. Lifting up the mats inside the driver's foot well I discovered that a rubber mat had been fixed down with this gunk to cover rot in the floorpan. He had then screwed a piece of angled metal to the side of the floor pan and through the rubber mat to cover the hole at the side. It passed 2 annual tests in Italy and 2 annual MoT tests in the UK, so perhaps it wasn't that shabby a repair after all ...

Now that I have disturbed it, I want to replace the rotten metal. I have a new front floorpan and have been looking at what is already there, much of which is sound. Because I have a new floorpan I was thinking of removing the whole of the old one, but can't see how it is attached - there is no obvious seam weld. Is it spot-welded? Would it be better to replace the old one completely or cut up the new panel to fit a hole around where the rot has been cut out? I'm new to this sort of surgery and will be practising recently learned mig welding for the first time on a real victim.
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post #2 of 11 (permalink) Old 08-16-2019, 08:09 AM
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Probably a good idea to assess your inner rocker panel as it may need replacing too if you are going to replace the floor. These things can quickly escalate!

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post #3 of 11 (permalink) Old 08-16-2019, 08:35 AM
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Quote:
Originally Posted by Jedispey View Post
Probably a good idea to assess your inner rocker panel as it may need replacing too if you are going to replace the floor. These things can quickly escalate!

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So true. may I say to check behind seats as well, if floor pan is shot, rear pan probably collected water too. Both sides are due for a check. I caught mine in time as to stop the rust just before the
"dam broke".
That's where I learned to weld, and weld, and weld again,,,, until I got it right

The pan is spot welded to the frame members and I found easiest to cut-out of the way, get a clean area to weld to & replace.
I'll look for the pictures & post later if I can find. GL

"No chance, no destiny, no fate can circumvent, change or control the firm resolve of a determined soul"

73 Spider
80 BMW e21(Sold, gone to Houston)
79 Spider (sold)
78 Spider (sold, gone to U K)
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Last edited by Alfaboutvegas; 08-16-2019 at 08:42 AM. Reason: forgot text
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post #4 of 11 (permalink) Old 08-16-2019, 01:20 PM Thread Starter
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Jedispey, Alfaaboutvegas,

Many thanks. There is a patch of pitting on top of the inner rocker so I'll cut that out and replace it, which will allow me to look inside the sill. As far as I can see, this is the only rot in the floorpan and apart from the holes, the rest of the driver's side appears sound.

Alfaboutvegas, pictures would be really helpful, thanks

Duncan

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post #5 of 11 (permalink) Old 08-16-2019, 04:52 PM
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Let me see if I can find a pic that will help

"No chance, no destiny, no fate can circumvent, change or control the firm resolve of a determined soul"

73 Spider
80 BMW e21(Sold, gone to Houston)
79 Spider (sold)
78 Spider (sold, gone to U K)
Greg
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post #6 of 11 (permalink) Old 08-16-2019, 05:07 PM
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The yellow highlites indicate approx spot welds
Of course that’s not all
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"No chance, no destiny, no fate can circumvent, change or control the firm resolve of a determined soul"

73 Spider
80 BMW e21(Sold, gone to Houston)
79 Spider (sold)
78 Spider (sold, gone to U K)
Greg
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post #7 of 11 (permalink) Old 08-16-2019, 08:19 PM
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Get a blair spotweld cutter and their lube stick - it's a long tiring process
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post #8 of 11 (permalink) Old 08-18-2019, 08:03 AM Thread Starter
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Thanks for the pictures, Alfaboutvegas, very helpful, and the advice Patpend2000. I'll post pictures when it's done

Duncan
1976 Alfa Spider 1600
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post #9 of 11 (permalink) Old 08-18-2019, 09:21 AM
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I have never done an Alfa floor pan, but several in VW and Porsche models. Can be satisfying/frustrating/expensive or any combination of the above. Sounds as though the PO was a flipper. Finding a shop to complete this work can be difficult. It's a dirty crappy job. Often the rust is too consuming
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post #10 of 11 (permalink) Old 08-18-2019, 01:02 PM Thread Starter
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It's a first for me, and I'm looking forward to the challenge. Currently the rust appears to be localized to the immediate area of the holes, but more may emerge as I attack it

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post #11 of 11 (permalink) Old 08-18-2019, 02:07 PM
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Good attitude to take dogwalker! Best to you & your endeavor. And if I can help, I'd be honored to do so. I may not be genius in my replies, I sometimes get "wonky" but I will give that which I know

"No chance, no destiny, no fate can circumvent, change or control the firm resolve of a determined soul"

73 Spider
80 BMW e21(Sold, gone to Houston)
79 Spider (sold)
78 Spider (sold, gone to U K)
Greg
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